Contents Setting the scene: A history and the position of biscuits - The beginnings of biscuit manufacturing - Ingredients and formulation development - Engineering and useful reading PART 1 MANAGEMENT OF TECHNOLOGY IN BISCUIT MANUFACTURE The role of the technical department in biscuit manufacture - The requirements of the technical (or technology) department - Selection of staff for the technical department - Facilities for the technical department - Liaison with other technical establishments - Support for purchasing - Support for training - Management of technical developments - Reference Quality management systems and (HACCP) in biscuit manufacture - Quality management - Management of product safety Quality control and good manufacturing practice (GMP) in the biscuit industry - Principles and management - Quality control tasks for finished product inspection - Quality control tasks for ingredient and packaging materials - Good manufacturing practice (GMP) - Hygiene surveys Process and efficiency control in biscuit manufacture and M Wilkes, MW Associates, - Process control and efficiency - Process audit - Process control checks and records for plants with no continuous monitoring sensors - Making process control measurements - Action procedures as a result of product measurements - Instrumentation for monitoring - Efficiency and integrated plant control - Outline of the instrumentation that is available - Troubleshooting - Energy efficiency and contacts
Product development in the biscuit industry - Product development - Facilities for process and product development - Assessing products - Establishing the product specification Sustainability in the biscuit industry R Brightwell, United Biscuits, - Key drivers for sustainability in the biscuit industry - Carbon emissions and energy use - Reducing water use - Reducing waste - Packaging - Other options for improving sustainability PART 2 MATERIALS AND INGREDIENTS FOR BISCUIT MANUFACTURE Choosing materials for biscuit production - Important technical aspects - Important commercial aspects - Programme for the meeting with a supplier Wheat flour and vital wheat gluten as biscuit ingredients, B Pareyt and J A Delcour, Katholieke Universiteit Leuven, Belgium - Flour from the viewpoint of the miller - Flour from the viewpoint of the biscuit manufacturer - Vital wheat gluten Meals, grits, flours and starches (other than wheat) - Cereal based materials - Non-cereal flours and starches and addresses Sugars and syrups as biscuit ingredients - Common sugar, sucrose - Syrups - Sugars and syrups from starches - glucose - Non-diastatic malt extract - Maillard reaction
- Polyols Fats and oils as biscuit ingredients G Atkinson, AarhusKarlshamn Ltd, - The role of fat in biscuits - The chemistry and physical properties of fats - Quality and handling issues of fats - Key characteristics of fats for biscuits - Quality control of fats - General specification requirements for oils and fats - Challenges for the biscuit manufacturer Emulsifiers (surfactants) and antioxidants as biscuit ingredients - Function of emulsifiers in biscuits - Types of food emulsifiers - Reduced fat biscuits - General use of emulsifiers in biscuit doughs - Application help - Anti-oxidants Milk products and egg as biscuit ingredients - Milk and milk products - Egg Dried fruits and nuts as biscuit ingredients - Dried grapes - Other dried fruits used in biscuits - Fruit pastes and syrups - Tree nuts - Peanuts, arachis or ground nut - Health problems associated with nuts Yeast and enzymes as biscuit ingredients - Yeast - Enzymes
Flavours, spices and flavour enhancers as biscuit ingredients - Sources and types of flavours - Suitability of a flavour material - Flavouring of biscuits - Flavour enhancers - Storage of flavours and quality control Additives as biscuit ingredients - Common salt (sodium chloride, NaCl) - Leavening agents - Processing aids - Food acids - Colours - Artificial sweeteners Chocolate and cocoa as biscuit ingredients - The flavour of chocolate - Chocolate viscosity - Cocoa butter, cocoa butter equivalents and hard butters - Definitions of cocoa and chocolate products - Types of chocolate - Supply and storage of chocolate - Chocolate drops and chips - Cocoa - Handling of chocolate and chocolate chips - Compound chocolate - Carob powder Packaging materials for biscuits and their influence on shelf life G L Robertson, Food Packaging Environment and University of Queensland, Australia - Packaging materials - Packaging and shelf life - Indices of failure (IoFs) - Package requirements to address (IoFs) PART 3 TYPES OF BISCUITS Classification of biscuits - Classification based on enrichment of the formulation
- Conversion of units - Reference Cream crackers - History and introduction to cream crackers - Mixing and fermentation of cream cracker doughs - Dough piece forming - Baking of cream crackers - Yields from fermented doughs Soda crackers - Dough preparation - Outline of typical soda cracker manufacturing techniques Savoury or snack crackers - General description - Manufacturing technology - Post-oven oil spraying Matzos and water biscuits - Matzos - Water biscuits - Typical recipes Puff biscuits - General description - Puff dough preparation - Baking of puff biscuits - Puff biscuit production techniques Hard sweet, semi-sweet and Garibaldi fruit sandwich biscuits - General description of this group of biscuits - Ingredients and recipes - Dough mixing - Mixer instrumentation - Dough piece forming - Instrumentation of the forming machine - Baking - Flavouring of biscuits - Cooling and handling of biscuits - Continental semi-sweet biscuits
- Garibaldi or fruit sandwich biscuits Short dough biscuits, B Pareyt and J A Delcour, Katholieke Universiteit Leuven, Belgium - Description of the group - Recipes and ingredients - Dough mixing - Dough piece forming - Instrumentation of the forming machine - Baking - Factors affecting dough piece spread during baking Deposited soft dough and sponge drop biscuits - Description of deposited biscuits - Description of sponge batter drops - Typical recipes Wafer biscuits - The wafer oven or wafer baker - Wafer sheet production - Batter mixing - Batter handling - Batter deposition and baking - Sheet handling, creaming and cutting - Process control of wafer production - Hollow rolled wafer sticks The position of biscuits in nutrition H Smith, Cereal Partners United Kingdom (CP), - Biscuits in our diets - The evolution of biscuit nutrition - Different biscuits for different people - Food labelling can help only when you understand it Miscellaneous biscuit-like products - Products that are made on a type of biscuit plant - Products that are not made on conventional biscuit plant PART 4 BISCUIT PRODUCTION PROCESSES AND EQUIPMENT
Bulk handling and metering of biscuit ingredients, reviewed by H Clark, Baker Perkins Ltd, - Bulk handling - Some technical aspects of bulk handling - Process control in bulk storage - Metering of ingredients to mixers Mixing and premixes in biscuit manufacture, reviewed by H Clark, Baker Perkins Ltd, - General conditions for mixing - Process control and instrumentation of mixers - Considerations in the selection of a mixer - Types of mixer available for biscuit doughs - Integrated mixing schemes in the future - Premixes Sheeting, gauging and cutting in biscuit manufacture, reviewed by H Clark, Baker Perkins Ltd, - Principles - Sheeters - Gauge rolls - Multiple roller gauging units - Dough relaxation units - Cutting - Cutter scrap dough handling - Dough piece garnishing and panning - Control of biscuit cutting machines - Operator maintenance requirements Laminating in biscuit manufacture, reviewed by H Clark, Baker Perkins Ltd, - Principles and techniques of laminating - Types of automatic laminator - Is laminating really necessary? - Process control during laminating Rotary moulding in biscuit manufacture, reviewed by H Clark, Baker Perkins Ltd, - General description of the rotary moulding machine - The formation of the dough piece - Dough piece weight control - Differential speeds of moulding roller and extraction roller
- Common difficulties that may be encountered with rotary moulders - Instrumentation of a rotary moulder - Disadvantages of a rotary moulder - The soft dough rotary moulder and roto depositor - Printing on dough pieces - Reference Extruding and depositing of biscuit dough, reviewed by H Clark, Baker Perkins Ltd, - General description of extruding and depositing machines for doughs - Process control of extruded and deposited biscuits - Sponge batter drops and lady finger biscuits Biscuit baking, reviewed by H Clark, Baker Perkins Ltd, - Changes to the dough piece during baking - Oven conditions - Typical baking profiles - Types of oven - Preparation and care of oven bands - Measurement and control in baking - Post oven oil spraying Biscuit cooling and handling, reviewed by H Clark, Baker Perkins Ltd, - Checking - Methods and speeds of cooling - Biscuit handling prior to packaging Secondary processing of biscuits, reviewed by H Clark, Baker Perkins Ltd, - General considerations - Sandwich creams - Icing - Jams, jellies, caramels and marshmallows - Chocolate and chocolate flavoured coatings Biscuit packaging and storage, reviewed by H Clark, Baker Perkins Ltd, - Functions of a pack
- Types of primary packages - Collation and feeding to wrapping machines - Biscuit size variations - Post wrapping operations - Process and quality control - Storage - Robotics and address Recycling, handling and disposal of waste biscuit materials, reviewed by H Clark, Baker Perkins Ltd, - Management of waste - Sources of waste materials - Estimating the size of the problem - Recycling - Disposal of waste materials which are not recycled PART 5 SUPPLIERS PRESENTATIONS